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激光制造業(yè)亟需組建優(yōu)秀的激光加工團隊，大力普及激光加工技術，設立激光加工教學、科研和生產(chǎn)基地，加大相關技術同步研究，將機器人技術、仿真技術應用等大規(guī)模地應用到城市軌道車輛制造中，發(fā)展我國自主特色的激光加工設備以及加工工藝。激光加工技術在城市軌道車輛制造中的應用，包括焊接、切割、表面改性、打標、快速成型、打孔及微細加工等。文章以城市軌道車輛為研究對象，闡述了先進激光焊接、激光切割在城市軌道車輛制造和輪軌表面處理等的原理和特點，分析了目前激光加工技術在城市軌道車輛制造中的特點和應用前景，為縮短與國外先進技術的差距，加快軌道交通技術儲備提供參考。

城市軌道交通已成為現(xiàn)代城市公共交通的主動脈，具有運量大、能耗低、效率高、污染小、準點率高等優(yōu)勢。中國如今已成為全球城市軌道交通建設投入的主力軍，甚至連許多二線城市都具備了軌道交通建設的條件與需求。
隨著中國政府“十三五”規(guī)劃的提出，國家發(fā)改委已批復了多地軌道交通的規(guī)劃，到2020年投資預計將超萬億。目前城市軌道車輛制造行業(yè)中，激光加工制造技術備受矚目，其很大程度上提升了城市軌道車輛制造水平；輕量化與高速化的趨勢，也持續(xù)為其提出新方向、新課題。

由于中國的城市軌道交通起步較晚，因此為了縮短與國外先進技術的差距，應引進、研究和消化當前最新技術及設計思路，加快軌道交通技術儲備，探究激光加工技術在城市軌道車輛制造中的應用。車輛激光焊接車輛轉向架以及車體是城市軌道車輛上的關鍵構成，材質(zhì)也經(jīng)歷了普通合金鋼、不銹鋼、鋁合金型材幾個階段。目前在城市軌道車輛制造中，逐步引入了激光焊接等新的加工工藝。

激光拼焊

激光拼焊是城市軌道車輛中最被看好的技術之一，屬于無接觸焊接，可將不同鋼種、厚度、表面處理的鋼板焊接成一個整體，區(qū)別于電阻滾壓縫焊，通過自由組合，使得構件變輕，零件變少，不僅提高可靠性，為寬體車制造奠定基礎，同時也改善了焊接質(zhì)量，提高了鋼材收得率，并降低了生產(chǎn)成本。

激光組焊

激光組焊在城市軌道車輛車身制造中舉足輕重，通過雙件組焊、多件組焊，將已切割成形的各類車身構件，焊接成白車身分總成，進而總裝成整車車身。激光組焊因其焊接強度高，可明顯改善車身強度、剛度及密閉性。焊接同時結合面小、變形小、焊接速度快、可焊材料范圍廣，適合于柔性化生產(chǎn)，投資效益好。但激光組焊技術也有明顯的缺點，如對夾具、被焊件、監(jiān)測精度等要求嚴格，焊接后檢測評價和返修困難，一次性投入大等。

激光-電弧復合焊

1) 不銹鋼車體制造。城市軌道車輛車體通常選用不銹鋼車體，由于電弧焊接后熱影響及變形等較嚴重，因此為改善外觀，過去常常進行涂裝作業(yè)，而現(xiàn)在則選用激光或電阻焊進行作業(yè)。

通過長期加工技術應用的實踐、積累及分析，不銹鋼接頭焊接技術規(guī)范、疲勞曲線、硬度、抗拉強度、屈服強度、等技術指標相繼被取得或檢驗，車體激光焊接樣件的制評亦完成。


2) 車輛轉向架制造。城市軌道車輛轉向架通常選用日本進口或國產(chǎn)的中厚合金鋼板材，同時多選用熔化極氣體保護焊。用于長直縫焊接的機械人手臂，已被各廠商所引進，來改善焊接穩(wěn)定性；而開具有不同規(guī)格的坡口，通常留較小鈍邊，以確保熔透。激光-電弧復合焊優(yōu)化焊接效率，顯示了激光和電弧的特點；同時減少了設備和人員投入，降低了焊接成本，并且可選較大鈍邊。


車輛激光切割

激光切割技術特性城市軌道車輛制造廠商已大量使用激光切割技術，其加工的產(chǎn)品有很多，如車體、內(nèi)裝板材、轉向架，常選用二維平面切割。激光可以加工出高精度、高切割斷面質(zhì)量的零件外形、輪廓和孔。

固體(或CO2)激光切割機通常適用于碳合金鋼、不銹鋼，同時也適用于鋁合金板，可達到理想斷面加工質(zhì)量和切割速度。以某企業(yè)為例，軌道車輛車體為不銹鋼，選用6 k W激光和剪板機對6 mm以下板材下料。車輛轉向架選用激光切割機對14 mm以下板材進行下料，其材料為Q345C低合金結構鋼。

下料環(huán)節(jié)激光切割

城市地鐵機車制造首先要準備相關材料，這個階段激光切割技術尤為重要。激光切割與火焰切割相比，切割速度快、工件變形小、加工精度高、適用性強、節(jié)料省錢、經(jīng)濟適用[16]，因此激光切割技術已被廣泛用于軌道車輛制造中。以某企業(yè)為例，其高速動車組車體選用激光和剪板機對6 mm以下板材下料，材料為鋁合金板材及型材。車輛轉向架選用6 k W激光切割機對12 mm以下板材下料[17]。

 

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1585J-M8CBJM-8M5 RJ45 Ethernet Media

1756-RM2K CLX Redundancy Module

188-K1D160 Miniature Circuit Breaker 16 A

194E-Y25M-1756-6N 25 A 194E Load switch

2090-CFBM7E7-CEAF02 2 m Length SpeedTec Extension Cable

2090-UXNFBY-S25 Y-Series 25 m Length Feedback Cable

BC646TRT050 Server 50 I/O RUNTIME SYS with Proficy GlobalCare

GC647IFPLRN00075 GCC iFIX Plus SCADA 75 I/O Run

IC200CBL545 VersaMax CPU001, 9-pin, RS-232 to DataPanel 3x/5x

IC646MPP050 Logic Developer PLC Professional 50 pack

IC647IFPRSRUNLMTK iFIX Profsnl SCADA Unlimited Server (M1 Kit Part)

IC660TSD100 Terminal Assembly for IC660BBD100/101

IC697CPM925RR CPU, 64MHz, 12K Discrete I/O, 1024K RAM, 80486DX2

IC800PCUBC02S030 Powercube flying lead interface cable configured for 200 steps/revolution and power save enabled. 3 meters

ControlLogix/1756 System 1756-OB16E 10-31 VDC ELEC FUSED OUTPUT 16 PTS (20 PIN)

Industrial Computers 6182H-10KEH15B VVCE 1000, KEYPAD, EXT MEM, CNET, AC

Process Control 9358-PBV01ENE RSBIZWARE BATCH FOR PLX VIEW ADDITIONAL CLIENTS

Operator Interface 2711P-RBK15 PV PLUS 1500 KEYPAD REPLACEMENT BEZEL

Support 9355-WAB1CENS SUPT RENEWAL CONTRACT FOR 9355WAB1CEN

Support 9351-SLRSR SUPT REINSTATEMENT CONTRACT FOR 9351SLRS

ControlNet Products 1786-RPFRXL CONTROLNET FIBER RING REPEATER - EXTRA LONG

RSI Software Products 9301-2SE2400ESU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (ES)

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Motion Control MPL-A320H-HK24AA MOTOR,SERVO,2.94NM,3500RPM,ENCDR,230V,BRK,5.1KG

Motion Control 2090-DANPT-16S12 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 1

BC647MQPU01 View for QuickPanel (Upgrade from QuickDesigner) with Proficy GlobalCare Complete and a hardware key

IC5008TAW0000 18" Inbligence Industrial PC, Standard Series Win2000

IC800MCUB12310XD Stepping Motor Cube, 175 oz-in with DeviceNet Option, NEMA 23

OC647IFESGCLNTCDVM iFIX Optn: ESig & ERec iClient Development (M4 Part)

20AD022A3AYYAEG1 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

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20G1ANF142JN0NNNNN PowerFlex 755 AC Packaged Drive

25C-E022N104 PowerFlex 527 15kW (20Hp) AC Drive

280-PWRM22B-M10 ArmorStart Three-Phase Power Media

FX1N-422-BD RS422C 通信用適配器

1492-M5X5H21-30 Connection Products

1494H-DN3N Heavy Duty Non-Fusible Safety Switch

軟啟動器 3RW44462BC34

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1585D-M4TBDM-9 Micro D-Code, QD Style Ethernet Media

1756-ENBT ControlLogix Enet/IP Comms Module

1794-OF4IXT Flex XT 4 Point Analog Output Module

194E-CA80 194E Load switch

2090-CCMCNDS-48AA01 Comms Cable Kinetix 3 MLX to Drive 1m

2090-DANPT-16S02 TL-Series 2 m Length Power Cable

ABICTDE0000/SER 10.5 inch Color TFT/ TCP Label/ 24VDC/ with HMI-CAB-C52 & HMI-CAB-C83/ UL/ cUL/ CE/ UL1604

GC646PCMS1C GlobalCare Complete for Change Management Electronic Signature Module 100 Pack